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MANUALE STAZIONE DI SERVIZIO
XXXXXX IT- EN-FR-DE-ES-PT-NL-EL
MSS Nexus 300 i.e. E3 ( 2008)

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Summary of Contents for Gilera 2008 MSS Nexus

  • Page 1 MANUALE STAZIONE DI SERVIZIO XXXXXX IT- EN-FR-DE-ES-PT-NL-EL MSS Nexus 300 i.e. E3 ( 2008)
  • Page 2 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
  • Page 3 Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.
  • Page 5: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
  • Page 7: Safety Rules

    MSS Nexus 300 i.e. E3 ( 2008) Characteristics This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well- ventilated, using special extractors if necessary;...
  • Page 8: Vehicle Identification

    MSS Nexus 300 i.e. E3 ( 2008) Characteristics Vehicle identification To read the chassis prefix, remove the lid «A» in the helmet compartment. The engine prefix «B» is stamped near the left shock absorber lower support. VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix ZAPM35600123456789 Engine prefix...
  • Page 9: Engine Technical Data

    MSS Nexus 300 i.e. E3 ( 2008) Characteristics Engine ENGINE TECHNICAL DATA Specification Desc./Quantity Type Single-cylinder, 4-stroke Cubic capacity 278 cm³ Bore x Stroke 75x63 mm Compression ratio 11 ± 0.5 : 1 Idle speed 1700 ± 100 rpm Timing system 4 valves, single overhead camshaft, chain-driven.
  • Page 10: Electrical Components

    MSS Nexus 300 i.e. E3 ( 2008) Characteristics Transmission RANSMISSION Specification Desc./Quantity Main drive Automatic expandable pulley variator with torque server, V- belt, automatic self-ventilating centrifugal dry clutch Capacities CAPACITY Specification Desc./Quantity Engine oil 1.3 l Transmission oil 250 cm³ Cooling system fluid ~ 1.8 l Fuel tank (reserve)
  • Page 11: Wheels And Tyres

    MSS Nexus 300 i.e. E3 ( 2008) Characteristics Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity Wheel rim type Light alloy rims. Front tyre Tubeless, 120/70 - 15'' 56P Rear tyre Tubeless, 140/60 - 14'' 64P Front rim 15'' x 3.00 Rear rim 14'' x 3.50 TYRE PRESSURE...
  • Page 12: Front Brake

    MSS Nexus 300 i.e. E3 ( 2008) Characteristics FRONT BRAKE Name Torque in Nm Screw tightening calliper to the support 24 ÷ 27 Pad fastening pin 19.6 ÷ 24.5 Calliper support plate - fork fixing screws 41 ÷ 51 Brake disc screws 8 ÷...
  • Page 13: Crankcase And Crankshaft

    MSS Nexus 300 i.e. E3 ( 2008) Characteristics Name Torque in Nm Camshaft retention plate screw 4 ÷ 6 RANSMISSION Name Torque in Nm Belt support roller screw 11 ÷ 13 Clutch unit nut on driven pulley 45 ÷ 50 Drive pulley nut 75 ÷...
  • Page 14 MSS Nexus 300 i.e. E3 ( 2008) Characteristics Cylinder - piston assy. CYLINDER - PISTON Specification Desc./Quantity Plunger diameter 74.967 +0.014 -0.014 mm Cylinder diameter 75 +0.038 +0.01 mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting cylinder-piston 75.01 ÷ 75.017 74.953 ÷...
  • Page 15 MSS Nexus 300 i.e. E3 ( 2008) Characteristics - Measure the diameter of the bearings on the pis- ton. Characteristic Standard diameter 16 +0.006 +0.001 mm - Calculate the piston pin coupling clearance. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS.
  • Page 16 MSS Nexus 300 i.e. E3 ( 2008) Characteristics - Check that the head coupling surface is not worn or misshapen. - Pistons and cylinders are classified according to diameter. The coupling must be made with those of the same type (M-M, N-N, O-O, P-P). Characteristic Maximum allowable run-out: 0.05 mm...
  • Page 17 MSS Nexus 300 i.e. E3 ( 2008) Characteristics CRANKSHAFT Specification Desc./Quantity Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm CHAR - 17...
  • Page 18 MSS Nexus 300 i.e. E3 ( 2008) Characteristics MAX. ADMISSIBLE DISPLACEMENT Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm CHAR - 18...
  • Page 19 MSS Nexus 300 i.e. E3 ( 2008) Characteristics Characteristic Crankshaft-crankcase axial clearance (H) 0.15 ÷ 0.43 mm - Using a bore gauge, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANK- SHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
  • Page 20 MSS Nexus 300 i.e. E3 ( 2008) Characteristics COUPLINGS BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING HALVES CATEGORY 29.024 ÷ 29.054 29.024 ÷ 29.054 29.018 ÷ 29.048 29.018 ÷ 29.048 Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat. 2). Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories.
  • Page 21 MSS Nexus 300 i.e. E3 ( 2008) Characteristics - Check the sealing surfaces for the intake and exhaust manifold. - Check that the bearings of the camshaft and the rocker pins exhibit no wear. - Check that the head cover surface is not worn. - Check that the coolant sealing pad exhibits no oxidation.
  • Page 22 MSS Nexus 300 i.e. E3 ( 2008) Characteristics - Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V". Characteristic Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm - If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°...
  • Page 23 MSS Nexus 300 i.e. E3 ( 2008) Characteristics MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Inlet: 4.96 mm Outlet: 4.945 mm - Calculate the clearance between valve and valve guide. - Check the deviation of the valve stem by resting it on a "V" shaped abutment and measuring the extent of the deformation with a comparator.
  • Page 24 MSS Nexus 300 i.e. E3 ( 2008) Characteristics INLET Specification Desc./Quantity Standard clearance: 0.013 - 0.04 mm Admissible limit: 0.08 mm OUTLET Specification Desc./Quantity Standard clearance: 0.025 ÷ 0.052 mm Admissible limit: 0.09 mm - Check that there are no signs of wear on the surface of contact with the articulated register terminal. - If the checks above give no failures, you can use the same valves.
  • Page 25 MSS Nexus 300 i.e. E3 ( 2008) Characteristics Specification Desc./Quantity Cam shaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm -Using a gauge, measure the cam height. TANDARD HEIGHT Specification Desc./Quantity Cam shaft check: Standard height Inlet: 30.285 mm Cam shaft check: Standard height Outlet: 29.209 mm Check the axial clearance of the camshaft...
  • Page 26 MSS Nexus 300 i.e. E3 ( 2008) Characteristics Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. OCKING LEVERS AND PIN DIAMETER Specification Desc./Quantity Internal rocker arm diameter: Standard diameter Diameter 12.000 - 12.011 mm Rocking lever pin diameter: Standard diameter Diameter 11.977 - 11.985 mm...
  • Page 27 MSS Nexus 300 i.e. E3 ( 2008) Characteristics inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa. N.B. MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK- CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON A GROUND PLANE ENGINE 300 SHIMMING...
  • Page 28: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 29: Specific Tools

    MSS Nexus 300 i.e. E3 ( 2008) Tooling SPECIFIC TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y014 Pliers to extract ø 15-mm bearings 005095Y Engine support 002465Y Pliers for circlips 020459Y Punch for fitting bearing on steering tube 020004Y Punch for removing fifth wheels from headstock...
  • Page 30 MSS Nexus 300 i.e. E3 ( 2008) Tooling Stores code Description 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting TOOL - 30...
  • Page 31 MSS Nexus 300 i.e. E3 ( 2008) Tooling Stores code Description 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter TOOL - 31...
  • Page 32 MSS Nexus 300 i.e. E3 ( 2008) Tooling Stores code Description 020648Y Single battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide TOOL - 32...
  • Page 33 MSS Nexus 300 i.e. E3 ( 2008) Tooling Stores code Description 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re- moval tool 020382Y011 adapter for valve removal tool 020393Y Piston fitting band 020412Y 15 mm guide TOOL - 33...
  • Page 34 MSS Nexus 300 i.e. E3 ( 2008) Tooling Stores code Description 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting/ removing the driven pulley clutch TOOL - 34...
  • Page 35 MSS Nexus 300 i.e. E3 ( 2008) Tooling Stores code Description 020456Y Ø 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide 020489Y Hub cover support stud bolt set 020428Y Piston position check support 020460Y Scooter diagnosis and tester TOOL - 35...
  • Page 36 MSS Nexus 300 i.e. E3 ( 2008) Tooling Stores code Description 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Belle for OD 47-mm bearings 020626Y Driving pulley lock wrench 001467Y013 Pliers to extract ø 15-mm bearings 020627Y Flywheel lock wrench TOOL - 36...
  • Page 37 MSS Nexus 300 i.e. E3 ( 2008) Tooling Stores code Description 020454Y Pin lock fitting tool 020467Y Flywheel extractor 020622Y Transmission-side oil guard punch 020480Y Petrol pressure check set 020244Y 15 mm diameter punch 020115Y Ø 18 punch TOOL - 37...
  • Page 38 MSS Nexus 300 i.e. E3 ( 2008) Tooling Stores code Description 020271Y Tool for removing-fitting silent bloc 020469Y Reprogramming kit for scooter diagnosis tester 020487Y Fork oil seal extractor TOOL - 38...
  • Page 39: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...
  • Page 40: Maintenance Chart

    MSS Nexus 300 i.e. E3 ( 2008) Maintenance Maintenance chart SCHEDULED MAINTENANCE TABLE I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE Clean the SAS air filter every 2 years * Replace every 2 years km x 1,000 Safety locks Spark plug...
  • Page 41 MSS Nexus 300 i.e. E3 ( 2008) Maintenance - Bring the reference mark onto the transmission side between the fan and the transmission cover as shown in the photograph. - Refit the spark plug. - Refit the plastic cap on the flywheel cover. - Adjust the spark gap to the contact position (no reference mark visible) and install it on engine be- tween the spark plug and spark plug cap...
  • Page 42: Spark Plug

    MSS Nexus 300 i.e. E3 ( 2008) Maintenance Spark plug Proceed as follows: 1. Remove the right side cover unscrewing the 3 «A» screws; 2. Disconnect the spark plug HV wire hood «B» ; 3. Unscrew the spark plug using the wrench sup- plied.
  • Page 43 MSS Nexus 300 i.e. E3 ( 2008) Maintenance Check -Park the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tightening it completely;...
  • Page 44: Air Filter

    MSS Nexus 300 i.e. E3 ( 2008) Maintenance Air filter Proceed as follows: 1. Unscrew the 9 fixing screws «A»; 2. Remove the air filter«B» CAUTION IF THE VEHICLE IS USED ON DUSTY ROADS, IT IS NEC- ESSARY TO SERVICE THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.
  • Page 45 MSS Nexus 300 i.e. E3 ( 2008) Maintenance Replacement Change oil and replace filter as indicated in the scheduled maintenance table. Empty the engine by draining the oil through drainage plug «B». To facilitate oil drainage, loosen the cap/dipstick «A». Once all the oil has drained through the drainage hole, unscrew and remove the oil cartridge filter «C ».
  • Page 46 MSS Nexus 300 i.e. E3 ( 2008) Maintenance few minutes and switch it off: after five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.
  • Page 47: Engine Oil Filter

    MSS Nexus 300 i.e. E3 ( 2008) Maintenance Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoring the level from the MIN to the MAX marks requires approx.
  • Page 48: Checking The Ignition Timing

    MSS Nexus 300 i.e. E3 ( 2008) Maintenance Checking the ignition timing - Remove the plastic cap on the flywheel cover -Turn the flywheel until the reference mark «T» on the rotor matches the reference mark on the fly- wheel cover as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure.
  • Page 49: Level Check

    MSS Nexus 300 i.e. E3 ( 2008) Maintenance Cooling system approx. 1.8 litres Level check Check coolant level when the engine is cold and as indicated in the scheduled maintenance table, following the steps below: - Place the vehicle on its centre stand and on flat ground.
  • Page 50 MSS Nexus 300 i.e. E3 ( 2008) Maintenance THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN, A MINIMUM LEVEL SHOULD NOT BE REACHED. IF THE LEVEL IS TOO LOW, CHECK AND FIX THE SYSTEM SEALS, IF RE- QUIRED.
  • Page 51: Headlight Adjustment

    MSS Nexus 300 i.e. E3 ( 2008) Maintenance SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS. Headlight adjustment - Place the scooter in use conditions, with tyres inflated to the prescribed pressure on flat ground at 10 m from a white screen placed in dim light.
  • Page 52: Index Of Topics

    INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 53: Difficult Starting

    MSS Nexus 300 i.e. E3 ( 2008) Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Poor performance OOR PERFORMANCE Possible Cause Operation Fuel pump...
  • Page 54: Brakes Overheating

    MSS Nexus 300 i.e. E3 ( 2008) Troubleshooting Possible Cause Operation Misshapen/worn valve seats Replace the head assembly Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings fitted properly Oil leaks from the couplings or from the gaskets...
  • Page 55: Noisy Suspension

    MSS Nexus 300 i.e. E3 ( 2008) Troubleshooting Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening Check the tightening of the top and bottom ring nuts. If irregu- larities continue in turning the steering even after making the above adjustments, check the rotation seats and the steering fifth wheels.
  • Page 56: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 57 MSS Nexus 300 i.e. E3 ( 2008) Electrical system Components arrangement ELE SYS - 57...
  • Page 58 MSS Nexus 300 i.e. E3 ( 2008) Electrical system 1. Remote controls Remove the legshield to reach it. A. Electric fan remote control B. High-beam light remote control C. Injection load remote control 2. Electric control management device Remove the legshield to reach it. 3.
  • Page 59 MSS Nexus 300 i.e. E3 ( 2008) Electrical system 7. Start-up remote control To reach it, remove the central chassis cover. 8. Stand button Remove the left footrest to reach them. 9. Horn To reach it, remove the lower cover. 10-11.
  • Page 60 MSS Nexus 300 i.e. E3 ( 2008) Electrical system 13. HV coil Remove the right side fairing to reach them. 14. Magneto flywheel The connector is located near the fuel pump. To reach it, remove the central chassis cover. 15. Oil pressure sensor On the engine, on the right-hand side of the vehi- cle.
  • Page 61: Ground Points

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system 17. Voltage regulator To reach it, remove the lower cover. 18.Wheel turning sensor In the front wheel, on the right-hand side. Ground points A. Ground points on the chassis To reach them, remove the right footrest. B.
  • Page 62: Checks And Inspections

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system Checks and inspections This section is devoted to the checks on the electrical system components. Immobiliser The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobilizer is an anti-theft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit.
  • Page 63 MSS Nexus 300 i.e. E3 ( 2008) Electrical system With the key switch in the OFF position: • there is battery voltage between termi- nals 5-26 and terminal 5-frame earth (fixed power supply). If there is no volt- age, check the key switch contacts, that fuses No.
  • Page 64 MSS Nexus 300 i.e. E3 ( 2008) Electrical system With the ignition key switch set to ON, check if there is battery voltage between the White-Black and Black cables. With MIU connector disconnected, check the con- tinuity between the Orange-White cable and pin 7 of the interface wiring .
  • Page 65 MSS Nexus 300 i.e. E3 ( 2008) Electrical system keys. The master and service keys must be used to code the system as follows: - Insert the Master key, turn it to «ON» and keep this position for two seconds (limit values 1 to 3 seconds).
  • Page 66: Diagnostic Codes

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system Diagnostic codes The immobiliser system is tested each time the ig- nition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit sta- tuses can be seen and various light codes dis- played.
  • Page 67: Ignition Circuit

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system • 3-flash code Diagnostic code - 1 flash The one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if nec- essary.
  • Page 68 MSS Nexus 300 i.e. E3 ( 2008) Electrical system No spark plug WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. HV coil primary resistance value: Disconnect the connector of the HV coil and meas- ure the resistance between the two terminals. Characteristic HV coil resistance primary value: ~ 0.9 Ω...
  • Page 69: Stator Check

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system Stator check Stator winding check-up WARNING THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED. 1) Remove the central chassis cover. 2) Disconnect the connectors between stator and regulator with the three yellow cables. 3) Measure the resistance between each of the yellow terminals and the other two.
  • Page 70: Voltage Regulator/Rectifier

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system - With the engine off and the panel at «ON» with the lights on, allow the battery voltage to stop at 12V. - Connect ammeter pliers to the 2 recharge positive poles in output from the regulator. - Start the engine and rev it up to a high engine speed while reading the value on the pincer.
  • Page 71: Horn Control

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system 1) Check fuses No. 3 and 10, and the key switch contacts. 2) Check the contacts of the stop buttons and the starter button. 3) Check the start-up remote control switch. 4) Check wiring continuity between the Green-Blue cable that connects the starter remote control to the injection electronic control unit (pin 24).
  • Page 72 MSS Nexus 300 i.e. E3 ( 2008) Electrical system Turn signals system check 1. Battery 2. Fuse No. 5 3. Key switch contacts 4. Fuse No. 7 5. Fuse No. 8 6. Turn indicator control device 7. Electric control management device 8.
  • Page 73 MSS Nexus 300 i.e. E3 ( 2008) Electrical system 6) Repeat the check between the Blue cable (pin 5) and the Pink cable (pin 4). 7) Use the turn indicator control device to check bulb wiring continuity . level indicators WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
  • Page 74 MSS Nexus 300 i.e. E3 ( 2008) Electrical system Specification Desc./Quantity Power: 12V - 5W Quantity: 1 Fuses The electric system is fitted with 2 fuse boxes: 1. Fuse box «A» 6 fuses located in the helmet compartment near the battery. 2.
  • Page 75 MSS Nexus 300 i.e. E3 ( 2008) Electrical system CAUTION BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE). FUSE BOX B Specification Desc./Quantity...
  • Page 76 MSS Nexus 300 i.e. E3 ( 2008) Electrical system Dashboard The digital display has two service symbols: SERVICE: The lamp should come on after reaching 1000 km, then every 10,000 km or 1 year after the last acti- vation. BELT: This lamp should come on and flash every 10,000 •...
  • Page 77 MSS Nexus 300 i.e. E3 ( 2008) Electrical system - Warning light preparation • Digital instrument The digital section provides the displays of: - Injection warning light (amber) - Low fuel warning light (amber) - Oil pressure warning light (red) - Turn signal warning light (green) - Immobilizer LED (red) The digital section of the instrument panel is com-...
  • Page 78 MSS Nexus 300 i.e. E3 ( 2008) Electrical system If the range drops below 40 km, the symbol appears automatically and flashes for 60 seconds. When the low fuel warning light comes on permanently, dashes appear instead of the range value. 6.
  • Page 79 MSS Nexus 300 i.e. E3 ( 2008) Electrical system If the button "CLOCK" is pressed for longer than 3 seconds, the figures showing the days start to flash. Set the day with the «ODO/SET» button. Press the "CLOCK" button again; the numbers showing the months start to flash. Set the month with the "ODO/SET"...
  • Page 80 MSS Nexus 300 i.e. E3 ( 2008) Electrical system The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline. CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
  • Page 81: Battery Installation

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system - Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a standard tester. - If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake or tilt the battery to eliminate any air bubbles formed during recharging.
  • Page 82 MSS Nexus 300 i.e. E3 ( 2008) Electrical system - Refit the battery cover Make sure that the terminals are connected correctly. When a new battery is installed, the correct time and date must be reset on the digital instrument panel («Clock» and «MODE button» section). CAUTION DO NOT REVERSE THE POLARITY: RISK OF SHORT CIRCUIT AND DAMAGE TO THE ELEC- TRICAL SYSTEM.
  • Page 83 MSS Nexus 300 i.e. E3 ( 2008) Electrical system Check the supply voltage. Keeping the connector in the position shown in the photo, check for battery voltage (12 V) with the polarity shown. If incorrect values are measured, check the elec- trical system and the digital instrument.
  • Page 84 MSS Nexus 300 i.e. E3 ( 2008) Electrical system ENGINE STOP SWITCH STARTER BUTTON LIGHT SWITCH TURN INDICATOR SWITCH ELE SYS - 84...
  • Page 85: Horn Button

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system HORN BUTTON HELMET COMPARTMENT LIGHT SWITCH Connectors INJECTION ELECTRONIC CONTROL UNIT 1. Injection telltale light (Brown-Black) 2. Rpm indicator (Green) 3. Not connected 4 Lambda probe negative terminal (Sky blue- Black) 5 Live supply (White-Black) 6.
  • Page 86 MSS Nexus 300 i.e. E3 ( 2008) Electrical system 17. Immobilizer warning light (Grey-Yellow) 18. Stand button (Brown-Red) 19. Not connected 20. Injection load remote control negative terminal (Black-Purple) 21. Not connected 22. HV coil negative terminal (Pink-Black) 23. Not connected 24.
  • Page 87 MSS Nexus 300 i.e. E3 ( 2008) Electrical system PICK-UP CONNECTOR 1. Positive from injection ECU (Red) 2. Negative from injection ECU (White) 3. Not connected CONNECTOR FOR ELECTRICAL CONTROL MANAGEMENT DEVICE 1. Live supply (White-Black) 2. Right turn indicator switch (White-Blue) 3.
  • Page 88 MSS Nexus 300 i.e. E3 ( 2008) Electrical system ENGINE TEMPERATURE SENSOR CONNEC- 1. Injection ECU temperature signal (Yellow-Pink) 2. Indicator temperature signal (Orange) 3. Ground (Sky blue-Green) 4. Indicator temperature signal (Sky blue-Black) ELECTRIC FAN CONNECTOR 1. Ground (Black) 2.
  • Page 89 MSS Nexus 300 i.e. E3 ( 2008) Electrical system FUEL PUMP CONNECTOR AND FUEL LEVEL TRANSMITTER 1. Not connected 2. Ground (Black) 3. Ground (Black) 4. Fuel level indicator (White-Green) 5. Positive from remote control (Black-Green) DIAGNOSIS CONNECTOR 1. Not connected 2.
  • Page 90 MSS Nexus 300 i.e. E3 ( 2008) Electrical system INSTRUMENT PANEL CONNECTOR 1. Wheel turning sensor signal (Red) 2. Wheel turning sensor signal (Sky blue) 3. Wheel turning sensor signal (Grey-Black) 4. Instrument panel lighting (Yellow-Black) 5. Rpm indicator (Green) 6.
  • Page 91: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 92 MSS Nexus 300 i.e. E3 ( 2008) Engine from vehicle Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo. Exhaust assy. Removal - Remove the Lambda probe from its support and disconnect it. - Remove the retainer clamp. - Undo the two exhaust manifold fixings on the head.
  • Page 93 MSS Nexus 300 i.e. E3 ( 2008) Engine from vehicle CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS RE- PLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP. Removal of the engine from the vehicle CAUTION SUPPORT THE SCOOTER ADEQUATELY. Disconnect the battery.
  • Page 94 MSS Nexus 300 i.e. E3 ( 2008) Engine from vehicle - Disconnect: - fuel piping and retainer clamp. - injector connector. - control unit connector. - Remove the coolant outlet pipe from the motor as indicated. - Remove the spark plug cap. - Remove the coolant temperature sensor con- nector indicated in the photograph.
  • Page 95 MSS Nexus 300 i.e. E3 ( 2008) Engine from vehicle - Remove the positive and negative wiring from the starter motor as shown in the photograph. - Disconnect the flywheel wiring connector. - Remove the clamp indicated. - Remove the cables from the retainer clamps on the flywheel cover.
  • Page 96 MSS Nexus 300 i.e. E3 ( 2008) Engine from vehicle When refitting the engine onto the scooter, carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter. - Check the engine oil level and if necessary, top it up with the recommended type.
  • Page 97 INDEX OF TOPICS NGINE...
  • Page 98: Automatic Transmission

    MSS Nexus 300 i.e. E3 ( 2008) Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.
  • Page 99: Removing The Driven Pulley Shaft Bearing

    MSS Nexus 300 i.e. E3 ( 2008) Engine - Remove the five screws on two different levels as well as the small casing. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Remove the bearing from the crankcase by means of: Specific tooling 020376Y Adaptor handle...
  • Page 100: Removing The Driven Pulley

    MSS Nexus 300 i.e. E3 ( 2008) Engine Plastic roller - Check that the roller does not show signs of wear and that it turns freely. - Remove the special clamping screws as indica- ted in the photograph - Check the outside diameter of the roller does not have defects that could jeopardise belt functioning - For refitting, place the roller with the belt contain- ment edge on the engine crankcase side...
  • Page 101: Inspecting The Clutch Drum

    MSS Nexus 300 i.e. E3 ( 2008) Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. Characteristic Max. value clutch bell Max. value: Ø 134.5 mm Clutch bell standard value Standard value: Ø...
  • Page 102: Removing The Clutch

    MSS Nexus 300 i.e. E3 ( 2008) Engine Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side. - Introduce the adapter ring No. 11 with the cham- fering facing the inside of the tool.
  • Page 103 MSS Nexus 300 i.e. E3 ( 2008) Engine DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD. Characteristic Check minimum thickness 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it.
  • Page 104 MSS Nexus 300 i.e. E3 ( 2008) Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Belle for OD 47-mm bearings - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø...
  • Page 105 MSS Nexus 300 i.e. E3 ( 2008) Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check the contact surface with the belt to make sure there are no flaws.
  • Page 106: Refitting The Driven Pulley

    MSS Nexus 300 i.e. E3 ( 2008) Engine Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure. - Fit the half-pulley over the bushing using the spe- cific tool.
  • Page 107 MSS Nexus 300 i.e. E3 ( 2008) Engine Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 123 mm acceptable limit after use: 118 mm Refitting the clutch...
  • Page 108 MSS Nexus 300 i.e. E3 ( 2008) Engine - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the specific tool.
  • Page 109: Removing The Driving Pulley

    MSS Nexus 300 i.e. E3 ( 2008) Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Driving belt - minimum width 19.5 mm Driving belt - standard width 21.3 ± 0.2 mm During the wear checks in the scheduled servicing programme, you are advised to check the rim bot- tom of the toothing does not show signs of inci-...
  • Page 110 MSS Nexus 300 i.e. E3 ( 2008) Engine - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling 020626Y Driving pulley lock wrench - Remove the fixing nut and the washer - Remove the stationary drive pulley half.
  • Page 111 MSS Nexus 300 i.e. E3 ( 2008) Engine Movable driving half-pulley bushing: Maxi- mum allowable diameter Ø 26.12 mm Sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm Sliding bushing: Minimum admissible diame- Ø 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm Roller: Minimum diameter permitted Ø...
  • Page 112 MSS Nexus 300 i.e. E3 ( 2008) Engine - Fit the steel shim in contact with the bushing and the stationary drive pulley. - Install the appropriate tool as described in the re- moval phase. -Tighten the nut with washer to the prescribed tor- que.
  • Page 113 MSS Nexus 300 i.e. E3 ( 2008) Engine End gear Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket. Removing the wheel axle - Remove the wheel axis complete with gear.
  • Page 114 MSS Nexus 300 i.e. E3 ( 2008) Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
  • Page 115 MSS Nexus 300 i.e. E3 ( 2008) Engine Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil guard, remove the transmission cover as described above. - Extract the driven pulley shaft from its bearing. - Remove the oil guard using a screwdriver, work- ing from inside the bearing and being careful not to damage the housing, make it come out of the...
  • Page 116 MSS Nexus 300 i.e. E3 ( 2008) Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - Heat the crankcase cover with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
  • Page 117 MSS Nexus 300 i.e. E3 ( 2008) Engine Refitting the hub cover bearings For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the special heat gun. - The three 15 mm bearings must be fitted using the appropriate tools.
  • Page 118: Flywheel Cover

    MSS Nexus 300 i.e. E3 ( 2008) Engine Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the centring dow- els.
  • Page 119: Removing The Stator

    MSS Nexus 300 i.e. E3 ( 2008) Engine Removing the hub cover - Remove the clip fixing the hose to the cylinder. - Remove the 10 fixings - Remove the flywheel cover. Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
  • Page 120 MSS Nexus 300 i.e. E3 ( 2008) Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Locking torques (N*m) Stator assembly screws (°) 3 ÷...
  • Page 121: Removing The Starter Motor

    MSS Nexus 300 i.e. E3 ( 2008) Engine Removing the starter motor - Remove the two screws indicated in the figure. - Take the starter motor out of its seat Removing the flywheel magneto - Remove the water pump shaft and crankshaft spline clip - Line up the two holes in the flywheel as shown in the photo...
  • Page 122 MSS Nexus 300 i.e. E3 ( 2008) Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the photo Specific tooling 020627Y Flywheel lock wrench - Remove the plate indicated in the photo. - Remove the flywheel nut with its washer - Do up the flywheel nut by three or four threads so that the flywheel does not fall accidentally on extraction...
  • Page 123 MSS Nexus 300 i.e. E3 ( 2008) Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.
  • Page 124: Removing The Intake Manifold

    MSS Nexus 300 i.e. E3 ( 2008) Engine - Using the special flywheel stop tool, tighten up the flywheel fixing nut to the prescribed torque -Refit the retention plate Specific tooling 020627Y Flywheel lock wrench Locking torques (N*m) Flywheel nut 94 ÷...
  • Page 125 MSS Nexus 300 i.e. E3 ( 2008) Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - Remove the parts listed below first: transmission cover, drive pulley with belt, oil sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the sprocket wheel separa- tion washer.
  • Page 126 MSS Nexus 300 i.e. E3 ( 2008) Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure.
  • Page 127: Removing The Cam Shaft

    MSS Nexus 300 i.e. E3 ( 2008) Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pins and the rocker arms from the flywheel side holes.
  • Page 128: Removing The Valves

    MSS Nexus 300 i.e. E3 ( 2008) Engine Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool. - Remove the lower spring supports. CAUTION REPLACE THE VALVES IN SUCH A WAY AS TO RECOG- NISE THEIR ORIGINAL POSITION ON THE HEAD.
  • Page 129 MSS Nexus 300 i.e. E3 ( 2008) Engine Inspecting the small end N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Crankcase - crankshaft - connecting rod Inspecting the wrist pin N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 130: Removing The Piston

    MSS Nexus 300 i.e. E3 ( 2008) Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the wrist pin snap ring onto the appropriate tool - With opening in the position indicated on the tool S = left...
  • Page 131 MSS Nexus 300 i.e. E3 ( 2008) Engine - By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres- sion ratio.
  • Page 132: Inspecting The Cylinder Head

    MSS Nexus 300 i.e. E3 ( 2008) Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retain- ing band, refit the cylinder as shown in the figure. N.B.
  • Page 133 MSS Nexus 300 i.e. E3 ( 2008) Engine Inspecting the valve sealings N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder Head Inspecting the valves N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 134: Inspecting The Cam Shaft

    MSS Nexus 300 i.e. E3 ( 2008) Engine Specific tooling 020306Y Punch for assembling valve seal rings 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Inspecting the cam shaft N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 135 MSS Nexus 300 i.e. E3 ( 2008) Engine - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - Holding this position insert the chain on the cam- shaft control pulley.
  • Page 136 MSS Nexus 300 i.e. E3 ( 2008) Engine - Fit the timing chain guide pad. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head. - Lubricate the stud bolt threading. - Tighten up the nuts to an initial pre-torque of 7±1 N·m - Tighten up the nuts to a second pre-torque of 10...
  • Page 137 MSS Nexus 300 i.e. E3 ( 2008) Engine - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque. N.B. BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COM- PRESSED AIR JET.
  • Page 138: Crankcase - Crankshaft

    MSS Nexus 300 i.e. E3 ( 2008) Engine Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge.
  • Page 139 MSS Nexus 300 i.e. E3 ( 2008) Engine CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE DRIVING SHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH- INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS. CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT.
  • Page 140 MSS Nexus 300 i.e. E3 ( 2008) Engine - Inspect the coupling surfaces on the crankcase halves for scratches or deformation, taking partic- ular care with the cylinder/crankcase surfaces and the crankcase halves surfaces. - Defects in the crankcase coupling gasket be- tween the crankcase halves or the mating surfaces shown in the diagram, could cause a drop in the oil pressure lubricating the main bearings and con-...
  • Page 141 MSS Nexus 300 i.e. E3 ( 2008) Engine - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposite the cylinder. - To prevent obstructions in the oil feeding chan- nels, the matching surface of the two half-bearings must be perfectly perpendicular to the cylinder ax- is, as shown in the figure.
  • Page 142 MSS Nexus 300 i.e. E3 ( 2008) Engine Studs Check that the stud bolts have not worked loose from their seat in the crankcase. Check the depth of stud bolt driving with a gauge, as indicated in the photograph. If it varies signifi- cantly from the driving depth indicated, it means that the stud bolt has yielded.
  • Page 143: Lubrication Circuit

    MSS Nexus 300 i.e. E3 ( 2008) Engine By working on two fitted cylinder head fixing nuts, nut and lock nut, as shown in the photograph, re- move the stud bolt from its seat. Clean the threaded seat on the carter thoroughly. Refit a new stud bolt and apply the special product on the threading crankcase side.
  • Page 144 MSS Nexus 300 i.e. E3 ( 2008) Engine ENG - 144...
  • Page 145: Oil Pressure Check

    MSS Nexus 300 i.e. E3 ( 2008) Engine Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch. - Check the oil pressure reading is between 0.5 and 1.2 atm with the engine idling at 1650 rpm and the oil at the required temperature (wait for at least one electric ventilation).
  • Page 146 MSS Nexus 300 i.e. E3 ( 2008) Engine Removal - First remove the transmission cover and the com- plete driving pulley - Install the base of the appropriate tool on the oil guard using the screws provided. Specific tooling 020622Y Transmission-side oil guard punch - Screw the threaded bar onto the base of the tool and extract the oil guard.
  • Page 147: Oil Pump

    MSS Nexus 300 i.e. E3 ( 2008) Engine - Orientate the oil guard by inserting the bracket which is part of the appropriate tool - Tighten the threaded bar onto the crankshaft as far as it will go. - Use the nut to move the base of the tool until you can see end of the oil guard driving stroke - Remove all of the tool components following the inverse procedure...
  • Page 148 MSS Nexus 300 i.e. E3 ( 2008) Engine Removal - Undo the two clamping screws in the figure and remove the cover over the pump control crown. - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes.
  • Page 149 MSS Nexus 300 i.e. E3 ( 2008) Engine - Check the clearance between the rotors in the position shown in the diagram using a thickness gauge. Measure the distance between the outer rotor and the pump body (see figure). - Check the axial clearance of the rotors using a trued bar as shown in the figure.
  • Page 150 MSS Nexus 300 i.e. E3 ( 2008) Engine - Fit the sprocket wheel with a new O-ring. - Fit the chain. - Fit the central screw and the belleville washer. Tighten to the prescribed torque. - Fit the oil pump cover by tightening the two screws to the prescribed torque.
  • Page 151 MSS Nexus 300 i.e. E3 ( 2008) Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defec- tive parts.
  • Page 152: Index Of Topics

    INDEX OF TOPICS INJEC NJECTION...
  • Page 153 MSS Nexus 300 i.e. E3 ( 2008) Injection INJECTION COMPONENTS Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Fuel injector Diagnostics socket connector Injection load remote control Electric fan Fuel pump Lambda sensor Engine rpm sensor HV coil Water temperature sensor MIU injection system This vehicle is fitted with an integrated injection and ignition system.
  • Page 154 MSS Nexus 300 i.e. E3 ( 2008) Injection In all conditions of use, mixture preparation is managed by modifying the injector opening time. The fuel supply pressure is kept constant based on the ambient pressure. The fuel supply circuit consists of: - Fuel pump - Fuel filter - Injector...
  • Page 155 MSS Nexus 300 i.e. E3 ( 2008) Injection Failures are detected and restored by the diag- nostic tester. In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles of use (cold start, running at regular engine temperature, stop).
  • Page 156 MSS Nexus 300 i.e. E3 ( 2008) Injection E: Intake circuit a. Dirty air filter b. Dirty by-pass circuit c. Faulty Stepper motor F: Other a. Incorrect distribution timing b. Wrong idle mixture c.Incorrect reset of the throttle valve position sensor 2 MIU system faults may be caused by loose connectors.
  • Page 157: Terminal Layout

    MSS Nexus 300 i.e. E3 ( 2008) Injection 10. Do not invert the polarity when fitting the battery. 11. To avoid damage, only disconnect and reconnect the MIU system connectors if required. Before reconnecting, check that the connectors are dry. 12.
  • Page 158 MSS Nexus 300 i.e. E3 ( 2008) Injection EMS circuit diagram 1. Battery 2. Fuse No. 5 3. Key switch contacts 4. Fuse No. 7 5. Fuse No. 8 6. Start-up remote control 7. Fuse No. 4 8. Fuse No. 1 9.
  • Page 159: Troubleshooting Procedure

    MSS Nexus 300 i.e. E3 ( 2008) Injection 20. Engine temperature sensor 21. Diagnostic socket connector 22. Injection ECU 23. Instrument panel 24. Digital instrument panel 25. Immobilizer warning light 26. Injection telltale light Troubleshooting procedure Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation...
  • Page 160 MSS Nexus 300 i.e. E3 ( 2008) Injection Possible Cause Operation Ignition advance Fuel supply Fuel pressure (low) Injector capacity (low) Injector seal (poor) Correctness of the parameters Coolant temperature Stepper throttle valve position intake air tempera- ture (steps and actual opening) Cleaning of the auxiliary air pipe and throttle valve;...
  • Page 161 MSS Nexus 300 i.e. E3 ( 2008) Injection Possible Cause Operation Intake air temperature sensor Intake system sealing (infiltrations) Intake manifold - head Throttle body - manifold Intake sleeve Filter box Fuel feed (low pressure) Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING...
  • Page 162 MSS Nexus 300 i.e. E3 ( 2008) Injection Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PROGRESS ON PICKUP Possible Cause Operation...
  • Page 163: Fuel Supply System

    MSS Nexus 300 i.e. E3 ( 2008) Injection Possible Cause Operation Intake system seal Intake sleeve Filter box TPS reset successful TPS reset successful Fuel supply Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness Fuel supply system The fuel supply circuit includes the electric pump, the filter, the pressure regulator, the electro-injector...
  • Page 164 MSS Nexus 300 i.e. E3 ( 2008) Injection Removing the butterfly valve Remove the helmet compartment. Remove the fuel piping clamping screw indicated in the figure. Remove the fast-release fitting from the injector support. Remove the injector connector. Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold.
  • Page 165 MSS Nexus 300 i.e. E3 ( 2008) Injection Remove the MIU ECU connector. Remove the clip fixing the throttle body to the air cleaner bellows. Remove the throttle control retainers as indicated in the photograph. Refitting the butterfly valve For refitting, carry out the removal operations but in reverse order paying particular attention to po- sition the reference marks of the air cleaner sleeve on the throttle body as indicated in the photograph.
  • Page 166: Electrical Data

    MSS Nexus 300 i.e. E3 ( 2008) Injection Pump supply circuit INJECTION LOADS Specification Desc./Quantity Battery 12V-14Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan remote control When switched to "ON", the fuel pump starts to rotate for two seconds and then stops.
  • Page 167 MSS Nexus 300 i.e. E3 ( 2008) Injection Check that the injection load 15A fuse No. 4 works properly. Check the efficiency of 7.5 A fuse No. 7 key-con- trolled control unit power supply. Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85;...
  • Page 168 MSS Nexus 300 i.e. E3 ( 2008) Injection Check the power supply line of the injection load remote control energising coil: After switching to "ON", make sure there is battery voltage, for two seconds, between the black/white cable and black-violet cable of the remote control base. If there is not, check the continuity of the black/white cable between fuse block and the remote control base and of the black/violet cable between pin 20...
  • Page 169 MSS Nexus 300 i.e. E3 ( 2008) Injection Check the presence of fixed voltage between the red/blue cable of the remote control base and earth. If not, check the continuity of the red/blue cable between the fuse box (No. 4 15A) and the remote control base.
  • Page 170 MSS Nexus 300 i.e. E3 ( 2008) Injection After switching to «ON» and for about 2 seconds, check that there is battery voltage between the Black-Green cable of the pump connector and the ground lead with the pump connector disconnec- ted.
  • Page 171 MSS Nexus 300 i.e. E3 ( 2008) Injection Check during regular operation by placing the ap- propriate tool between the pump and the injector. With the battery voltage> 12 V check that the fuel pressure is 2.5 BAR and that the input current is 1.4 to 1.8 A With the battery voltage >...
  • Page 172 MSS Nexus 300 i.e. E3 ( 2008) Injection Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support INJEC - 172...
  • Page 173 MSS Nexus 300 i.e. E3 ( 2008) Injection Inspecting the injector circuit INJECTION LOADS Specification Desc./Quantity Battery 12V-14Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan remote control Check the resistance at the injector ends: 14.5 ±...
  • Page 174 MSS Nexus 300 i.e. E3 ( 2008) Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
  • Page 175 MSS Nexus 300 i.e. E3 ( 2008) Injection Check the power supply line of the injection load remote control energising coil: After switching to "ON", make sure there is battery voltage, for two seconds, between the black/white cable and black-violet cable of the remote control base. If there is not, check the continuity of the black/white cable between fuse block and the remote control base and of the black/violet cable between pin 20...
  • Page 176 MSS Nexus 300 i.e. E3 ( 2008) Injection Check the presence of fixed voltage between the red/blue cable of the remote control base and earth. If not, check the continuity of the red/blue cable between the fuse box (No. 4 15A) and the remote control base.
  • Page 177 MSS Nexus 300 i.e. E3 ( 2008) Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to «ON» and check if there is voltage, with injector disconnected and control unit connected, between the Black-Green cable of the injector con- nector and the ground lead...
  • Page 178 MSS Nexus 300 i.e. E3 ( 2008) Injection Install the appropriate tool for checking fuel pres- sure and position the manifold over a container graduated by at least 100 cm³. Connect the injec- tor with the cable making up part of the supply for the injection tester.
  • Page 179: Components Location

    MSS Nexus 300 i.e. E3 ( 2008) Injection Components location INJECTION COMPONENTS Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Fuel injector Diagnostics socket connector Injection load remote control Electric fan Fuel pump Lambda sensor Engine rpm sensor HV coil Water temperature sensor Tachometer...
  • Page 180 MSS Nexus 300 i.e. E3 ( 2008) Injection With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of approx- imately 20°...
  • Page 181 MSS Nexus 300 i.e. E3 ( 2008) Injection With the revolution sensor connector disconnec- ted and interface wiring disconnected from the control unit, check that the red and white cables (pins 13 - 15) are isolated from each other and in- sulated from the ground connection.
  • Page 182 MSS Nexus 300 i.e. E3 ( 2008) Injection This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'. - Magnetisation time The coil magnetisation time is controlled by the control unit.
  • Page 183 MSS Nexus 300 i.e. E3 ( 2008) Injection Check the power supply line of the injection load remote control energising coil: After switching to "ON", make sure there is battery voltage, for two seconds, between the black/white cable and black-violet cable of the remote control base. If there is not, check the continuity of the black/white cable between fuse block and the remote control base and of the black/violet cable between pin 20...
  • Page 184 MSS Nexus 300 i.e. E3 ( 2008) Injection Check the presence of fixed voltage between the red/blue cable of the remote control base and earth. If not, check the continuity of the red/blue cable between the fuse box (No. 4 15A) and the remote control base.
  • Page 185 MSS Nexus 300 i.e. E3 ( 2008) Injection Check there is voltage between pins 22 and 26 of the interface wiring for around two seconds when switching to «ON». Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con- trol disconnected.
  • Page 186: Coolant Temperature Sensor

    MSS Nexus 300 i.e. E3 ( 2008) Injection Coolant temperature sensor EMPERATURE SENSOR Specification Desc./Quantity Engine stop switch Water temperature sensor With the control unit side connector disconnected and the coolant temperature sensor connector connected, check the resistance between pins 9 and 26 in relation to the engine temperature.
  • Page 187 MSS Nexus 300 i.e. E3 ( 2008) Injection nected, check the insulation between the two light blue/green and pink/yellow cables Zeroing the throttle Resetting the throttle valve position signal (TPS reset) The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated. Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of air under pre-set reference conditions.
  • Page 188 MSS Nexus 300 i.e. E3 ( 2008) Injection Connect the diagnostic tester. Switch to «ON». Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve with the control is supporting the stop screw.
  • Page 189 MSS Nexus 300 i.e. E3 ( 2008) Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
  • Page 190: Lambda Probe

    MSS Nexus 300 i.e. E3 ( 2008) Injection Lambda probe INJECTION LOADS Specification Desc./Quantity Battery 12V-14Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan remote control The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen content in the exhaust gas.
  • Page 191 MSS Nexus 300 i.e. E3 ( 2008) Injection Check that the injection load 15A fuse No. 4 works properly. Check the efficiency of 7.5 A fuse No. 7 key-con- trolled control unit power supply. Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85;...
  • Page 192 MSS Nexus 300 i.e. E3 ( 2008) Injection Check the power supply line of the injection load remote control energising coil: After switching to "ON", make sure there is battery voltage, for two seconds, between the black/white cable and black-violet cable of the remote control base. If there is not, check the continuity of the black/white cable between fuse block and the remote control base and of the black/violet cable between pin 20...
  • Page 193: Signal Control

    MSS Nexus 300 i.e. E3 ( 2008) Injection Check the presence of fixed voltage between the red/blue cable of the remote control base and earth. If not, check the continuity of the red/blue cable between the fuse box (No. 4 15A) and the remote control base.
  • Page 194 MSS Nexus 300 i.e. E3 ( 2008) Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Place the tips of the multimeter between pins 4 (-) and 11 (+) With the engine running at idle speed, check that...
  • Page 195: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...
  • Page 196: Removing The Front Wheel

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the fixing nut from the wheel axle on the left side of the vehicle. - Loosen the two screws fixing the wheel axle clamp and remove the clamp.
  • Page 197 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch (consisting of adaptor handle, 24 mm adaptor and 15 mm guide) from the brake disc side to permit the removal of the opposite side bearing and the spacer bushing.
  • Page 198 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020412Y 15 mm guide 020201Y Spacer bushing driving tube - Refit the cap and tighten the five fixing screws.
  • Page 199: Refitting The Front Wheel

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Turn over the wheel and insert the internal spacer with the part fitted with the Seeger ring facing the bearing on the brake disc side. - Heat the bearing seat on the side the brake disc with the heat gun.
  • Page 200: Front Fork

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions Removal - Remove the two handlebar covers and the upper part of the shield back plate proceeding as indica- ted in the «Bodywork» chapter. - Remove the handlebar wiring retaining straps and disconnect the electric connectors from the brake levers.
  • Page 201 MSS Nexus 300 i.e. E3 ( 2008) Suspensions Overhaul - Support the fork in a vice. - Loosen the two tightening screws of the stem supporting clamp. - Unscrew the stem closing cap and slide off the complete fork leg from the corresponding support. CAUTION THE STEM CLOSING CAP KEEPS THE MAIN SPRING PRELOADED.
  • Page 202 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Remove the stem dust guard with a screwdriver. - Remove the circlip retaining the oil seal. - Take out the stem. - Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace the damaged parts.
  • Page 203: Component Check

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Take out the oil seal using the appropriate tools. - Fit the tie rod into the oil seal. - Insert in sequence the two half-rings per Ø 35- mm stems. Specific tooling 020487Y Fork oil seal extractor - Hold the tie rod manually so that it does not fall into the fork leg and/or that both half-rings are not...
  • Page 204 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Check that the fork leg is not cracked or broken in the attachments. - Check that the stem is not scored, dented or dis- torted. - Check that the stop bushing for the hydraulic rod is correctly fixed through caulking.
  • Page 205 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Check that the closing cap O-ring of the stem is in good conditions. Refitting - First grease the splitting chamber of the two seal- ing lips of a new oil seal. - Fit the sealing ring on the stem and keep the identification words facing upwards.
  • Page 206 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Lock hydraulic rod rotation using a 19-mm hex- agonal spanner. - Fit the oil seal retaining circlip. - Grease and fit a new dust guard. - Fit the fork leg together with the stem on the fork supporting clamp until it stops.
  • Page 207 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Refill the fork leg with the recommended product to the prescribed amount. Recommended products AGIP FORK 7.5 W Oil for front fork Hydraulic fluid SAE 7.5 W Characteristic Oil quantity per stem 133 ±...
  • Page 208: Steering Column

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions Steering column Removal - Remove the front wheel. - Remove the front mudguard - Remove the front brake calliper - Remove the shield back plate upper side. - Remove the pin mounting the handlebar to the steering tube.
  • Page 209 MSS Nexus 300 i.e. E3 ( 2008) Suspensions Refitting - Fit the lower steering fifth wheel on the steering tube. - Fit the fork together with the lower steering fifth wheel on the headstock and hold it so that it does not fall.
  • Page 210 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Fit the cover plate. - Insert the spacer. - Insert the lower tightening ring nut, screw until it stops and, with the specific tool, tighten to the pre- scribed torque. Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m) Steering tube lower ring nut...
  • Page 211: Steering Bearing

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Fit the spacer between the two ring nuts on the steering tube in the position indicated. - Insert the upper tightening ring nut, screw until it stops and, with the specific tool, tighten to the in- dicated torque.
  • Page 212 MSS Nexus 300 i.e. E3 ( 2008) Suspensions Removal - Clean thoroughly and visually inspect if the com- ponents are in good conditions. - Check the upper steering fifth wheel for wear. - Check the lower steering fifth wheel for wear. - Visually inspect that the steering fifth wheel tracks, the headstock and the steering tube exhibit no scores or abnormal wear.
  • Page 213 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Repeat the procedure for the lower steering fifth wheel track. - Remove the lower fifth wheel seat on the steering tube using the specific tool. Specific tooling 020004Y Punch for removing fifth wheels from headstock SUSP - 213...
  • Page 214 MSS Nexus 300 i.e. E3 ( 2008) Suspensions Refitting STEERING FIFTH WHEEL TRACK FITTING - Thoroughly clean the track seats on the head- stock and the steering tube. - Fit the new tracks of the headstock with the spe- cific tool. - Screw the nut until the tracks are fully inserted.
  • Page 215: Removing The Rear Wheel

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions ing surface of driven pulley spring (only pulley side) Soap-based lithium and zinc oxide grease con- taining NLGI 2; ISO-L-XBCIB2 Rear Removing the rear wheel Remove the full muffler assembly. - Remove the cotter pin, the cap, the wheel axle fixing nut and the outer one of the two spacers.
  • Page 216: Refitting The Rear Wheel

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Remove the 5 bolts of the wheel and remove Refitting the rear wheel To fit, follow the removal steps but in the reverse sequence, being careful to fit the spacers on the wheel axle as shown in the photograph.
  • Page 217 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - remove the spring anchoring the swinging arm to the frame as shown in the photo - Remove the two screws fixing the buffer support bracket to the frame - Undo the nut on the LHS shown in the figure and remove the corresponding bolt from the opposite side.
  • Page 218 MSS Nexus 300 i.e. E3 ( 2008) Suspensions Overhaul - Check there is no sticking in the movement of the connection of the swinging arm on the engine side to the swinging arm on the frame side. - Check the axial clearance between the two swinging arms using a feeler thickness gauge Characteristic Standard clearance...
  • Page 219 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Using a suitable pin remove the roller casings as shown in the photographs - Using an appropriate tool plant new roller cas- ings, being careful to position the bearings with the O-rings facing outwards Specific tooling 020244Y 15 mm diameter punch...
  • Page 220 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Lubricate roller casings and the plastic bushings with grease - Insert the spacers - Assemble the two arms with the relative bolt in the position shown in the photograph - Adjust the bolt as shown in the photograph - Position the frame side swinging arm with the most protruding part pointing towards the silent block side as shown in the photograph...
  • Page 221 MSS Nexus 300 i.e. E3 ( 2008) Suspensions - Hold the full silent bloc bracket in the clamp - Using the appropriate tool, remove the silent bloc from the bracket from the side corresponding to the inside of the vehicle. This is to guarantee the tool is centred properly on the support - Install a new silent bloc, making sure it aligns properly with the reference tooth.
  • Page 222: Shock Absorbers

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions -Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque. Locking torques (N*m) Engine and vehicle side swinging arm junction bolt 33 ÷ 41 Nm Swinging arm pin - Engine 64 - 72 Body shell - Swinging arm pin 76 ÷...
  • Page 223: Side Stand

    MSS Nexus 300 i.e. E3 ( 2008) Suspensions Centre-stand REMOVAL - Use a jack to support the vehicle properly. - Remove the two return springs from the centre stand. - Undo the nut shown in the figure. - Remove the bolt from the right side. - Remove the centre stand.
  • Page 224: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 225: Rear Brake Calliper

    MSS Nexus 300 i.e. E3 ( 2008) Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the rear wheel. - Remove the two rear brake calliper devices fas- tening them to the support as shown in the photo- graph.
  • Page 226 MSS Nexus 300 i.e. E3 ( 2008) Braking system - Remove the internal parts from the floating body with short blasts of compressed air through the brake liquid pipe to facilitate expelling the plung- ers. - Check: • that the plates and the body are whole and in good condition;...
  • Page 227: Front Brake Calliper

    MSS Nexus 300 i.e. E3 ( 2008) Braking system - Hold the pads in the correct position and insert the calliper in the brake disc. - Fix the support calliper by means of the two screws at the specified torque - Secure the pipe fitting to the calliper at the specified torque.
  • Page 228 MSS Nexus 300 i.e. E3 ( 2008) Braking system - Remove the internal parts from the floating body with short blasts of compressed air through the brake liquid pipe to facilitate expelling the plung- ers. - Check: • that the plates and the body are whole and in good condition;...
  • Page 229: Rear Brake Disc

    MSS Nexus 300 i.e. E3 ( 2008) Braking system - Hold the pads in the correct position and insert the calliper in the brake disc. - Fix the support calliper by means of the two screws at the specified torque - Secure the pipe fitting to the calliper at the specified torque.
  • Page 230: Disc Inspection

    MSS Nexus 300 i.e. E3 ( 2008) Braking system Brake disc screws 8 ÷ 10 Disc Inspection - Remove the rear brake calliper. - Check the disc thickness with a micrometer Characteristic Standard thickness: 5 +0.2-0.1 mm Disc thickness at wear limit 4.5 mm - Repeat the measurement at no fewer than six points on the disc.
  • Page 231 MSS Nexus 300 i.e. E3 ( 2008) Braking system Removal - Remove the front wheel. - Undo the five clamping screws shown in the pho- tograph Refitting For fitting, position the disc correctly using the arrow stamped on it as reference. - Do up the screws to the prescribed torque and apply the recommended product N.B.
  • Page 232: Front Brake Pads

    MSS Nexus 300 i.e. E3 ( 2008) Braking system • Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted properly. The protrusion, measured near the external edge of the disc, must be less than 0.1 mm. •...
  • Page 233: Rear Brake Pads

    MSS Nexus 300 i.e. E3 ( 2008) Braking system See also Front brake calliper Refitting To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque.
  • Page 234 MSS Nexus 300 i.e. E3 ( 2008) Braking system Removal Proceed as follows: - Remove the rear brake calliper. - Loosen the two pins shown in the figure that lock the two pads. - Remove the pads, being careful with the pad spring clamp.
  • Page 235 MSS Nexus 300 i.e. E3 ( 2008) Braking system Refitting To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque. N.B.
  • Page 236 MSS Nexus 300 i.e. E3 ( 2008) Braking system System bleed calliper fitting: 12 ÷ 16 Nm Front - Remove the rubber hood from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered. - With the right-hand brake lever, load the system and bring it up to the required pressure.
  • Page 237 MSS Nexus 300 i.e. E3 ( 2008) Braking system - Upon refitting, tighten up the fitting to the speci- fied torque and bleed the system. CAUTION ALWAYS USE NEW COPPER WASHERS. Locking torques (N*m) Brake fluid pump-hose fitting Fixing 16 ÷ 20 screws for handlebar control assembly U- bolts 7 ÷...
  • Page 238: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 239: Circuit Diagram

    MSS Nexus 300 i.e. E3 ( 2008) Cooling system Circuit diagram A = Expansion tank B = Radiator C = Radiator intake pipe D = Water pump E = Delivery pipe to cylinder F = By-Pass pipe G = Thermostat H = Radiator delivery pipe Electric fan check - Check and, if necessary, restore the correct battery voltage.
  • Page 240 MSS Nexus 300 i.e. E3 ( 2008) Cooling system Characteristic Battery voltage - Check that the electric ventilation relay is working properly. - If the relay is not working, replace it. - If the relay is operating, remove it and jump the red-green and red-black wires (85 - 86);...
  • Page 241 MSS Nexus 300 i.e. E3 ( 2008) Cooling system - Tighten the bleed valve respecting the maximum torque. - Bring the coolant up to the correct level inside the expansion tank Locking torques (N*m) Bleed screw Thermostat Removal - Remove the helmet compartment inspection cov- - Place a + 2.0 l container under the vehicle to col- lect the coolant.
  • Page 242 MSS Nexus 300 i.e. E3 ( 2008) Cooling system Check 1) Visually inspect that the thermostat is not dam- aged. 2) Fill a metal container with approx. 1 litre of wa- ter. Immerse the thermostat, and keep it in the centre of the container.
  • Page 243 INDEX OF TOPICS CHAS HASSIS...
  • Page 244 MSS Nexus 300 i.e. E3 ( 2008) Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat - Remove the two clamping screws on the frame. - Remove the control button of the undersaddle light.
  • Page 245: Instrument Panel

    MSS Nexus 300 i.e. E3 ( 2008) Chassis Instrument panel - Remove the instrument panel. - Loosen the five fixing nuts of the instrument pan- Front handlebar cover - Remove the rear handlebar cover. - Remove the left and right frames of the brake pump secured with two retaining fins.
  • Page 246: Central Tunnel

    MSS Nexus 300 i.e. E3 ( 2008) Chassis Headlight assy. - Remove the centre cover of the shield. - Remove the 4 front retainers of the front light as- semblies. - To remove the right-hand light assembly, remove the screw located near the cover of the expansion tank.
  • Page 247 MSS Nexus 300 i.e. E3 ( 2008) Chassis - Remove the saddle together with the hinge. - Open the fuel tank flap. - Undo the screw indicated in the figure. - Undo the three screws indicated in the figure. N.B. THE OTHER 3 SCREWS HAVE ONLY AN AESTHETIC FUNCTION - Undo and remove from both vehicle sides the...
  • Page 248 MSS Nexus 300 i.e. E3 ( 2008) Chassis - Working from both sides, undo the screw indica- ted and release the retaining tongues to remove the side air deflectors. - Undo from both sides the screw indicated in the figure. - Remove the central tunnel sliding it from the tongues.
  • Page 249 MSS Nexus 300 i.e. E3 ( 2008) Chassis FRONT LOWER FRAME: - Using a screwdriver, remove the «GILERA» clip- on badge. - Undo and remove the screw under the badge. - Undo and remove the screw «A». - Taking care not to damage the plastic tongues, remove the front lower frame sliding it upwards from bottom to top.
  • Page 250: Front Turn Indicators

    MSS Nexus 300 i.e. E3 ( 2008) Chassis - Undo and remove the two screws «B» and the four screws «C». - Remove the frame sliding it from the tongues. FRONT TURN INDICATORS: - Undo and remove the three screws indicated. - Disconnect the front turn indicator connector.
  • Page 251 MSS Nexus 300 i.e. E3 ( 2008) Chassis - Remove the hand guards unscrewing, from both sides, the two screws «A» collecting the washers and the screw «B». - Undo the central screw. - Undo the two screws indicated. - Undo the rider footrest fixing screw «C» and the spoiler fixing screw «D».
  • Page 252 MSS Nexus 300 i.e. E3 ( 2008) Chassis INSTRUMENT PANEL: - Remove the windshield. - Remove the rear handlebar cover. - Remove the front handlebar cover - Remove the handlebar. - Undo and remove the two screws «A». - Working from both vehicle sides, undo and re- move the screw «B».
  • Page 253 MSS Nexus 300 i.e. E3 ( 2008) Chassis - Undo and remove the expansion tank cap and the gasket below. - Remove the instrument panel and release the in- strument panel connector «E» and the instrument panel lighting connector «F». Remove the instru- ment panel.
  • Page 254 MSS Nexus 300 i.e. E3 ( 2008) Chassis Removing the ignition key-switch when on *off* - Remove the lower shield back plate. - Unscrew the seat opening transmission from the side. - Remove in advance the ring of the immobiliser antenna.
  • Page 255 MSS Nexus 300 i.e. E3 ( 2008) Chassis - In order to remove the wheel housing it is necessary to remove the front brake hose to the tank and combination with the splitter. To remove the front wheel housing, proceed as follows: - Remove the spoiler.
  • Page 256: Passenger Footrest

    MSS Nexus 300 i.e. E3 ( 2008) Chassis - Using a jointed wrench between the helmet com- partment and the chassis pipes, loosen the two rear fixing nuts and then disconnect the light stud bolts from the support extensions. - Remove the light and disconnect the bulb holder by turning it through 30°...
  • Page 257 MSS Nexus 300 i.e. E3 ( 2008) Chassis RIGHT AND LEFT FOOTREST: - Working from both vehicle sides, remove the mat. - Undo and remove the two screws «B» and the four screws «C». - Remove the footrest RIDER FOOTREST: To remove the rider footrest, proceed as follows: - Remove the central cover.
  • Page 258 MSS Nexus 300 i.e. E3 ( 2008) Chassis PASSENGER FOOTREST: - Remove the side fairings. - Unscrew the nut «A» from both vehicle sides and release the footrests. RIGHT AND LEFT FOOTREST: - Working from both vehicle sides, remove the mat. - Undo and remove the two screws «B»...
  • Page 259 MSS Nexus 300 i.e. E3 ( 2008) Chassis Side fairings - Remove the rear central cover. - Remove the passenger handles. - Remove the lower cover. - Remove the lower side cover. - Remove the eight screws shown in the figure (four on each side).
  • Page 260: Rear Mudguard

    MSS Nexus 300 i.e. E3 ( 2008) Chassis - Remove the three screws indicated in the figure. License plate holder - Remove the rear lower central cover. - Remove the four fixing screws (two per side) and disconnect the electric connectors. - To access the license plate light bulb, remove the two fixing screws of the support rear cover and ex- tract the complete bulb holder.
  • Page 261 MSS Nexus 300 i.e. E3 ( 2008) Chassis - From the left side of the vehicle, undo the two screws «B». - Remove the rear mudguard. Helmet bay To remove the helmet compartment, proceed as follows: - Remove the saddle. - Remove the battery.
  • Page 262: Fuel Tank

    MSS Nexus 300 i.e. E3 ( 2008) Chassis Fuel tank To remove the fuel tank, proceed as follows: N.B. THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY. - Remove the shield back plate. - Remove the central chassis cover. - Remove the footrest.
  • Page 263: Front Mudguard

    MSS Nexus 300 i.e. E3 ( 2008) Chassis - Release the fuel pipe removing the clamp «C». - Disconnect the fuel probe connector. - Undo the two tank fixing screws. - Remove the tank through the front lower part of the vehicle.
  • Page 264: Radiator Fan

    MSS Nexus 300 i.e. E3 ( 2008) Chassis Radiator fan - Remove the spoiler. - Remove the front fork. - Remove the plate supporting bracket for the horn and voltage regulator by loosening the two fixing screws shown in the figure in order to release the two lower retainers of the wheel housing.
  • Page 265 MSS Nexus 300 i.e. E3 ( 2008) Chassis To remove the windshield supports, proceed as follows: - Remove the caps and the gaskets on the two windshield supports. - Remove the FRONT UPPER FRAME. - Working from both vehicle sides, undo and re- move the two screws «A».
  • Page 266: Lower Cover

    MSS Nexus 300 i.e. E3 ( 2008) Chassis - First disconnect the negative terminal «A», then the positive terminal «B». - Remove the battery. Lower cover - Remove the two screws of the lower spoiler (long type). - Remove the 2 screws located under the footrests. - Remove the 4 union screws with the front wheel housing cover.
  • Page 267 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 268 MSS Nexus 300 i.e. E3 ( 2008) Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection - Visually check that there is a yellow mark on the following clamps: FRONT WHEEL •...
  • Page 269 MSS Nexus 300 i.e. E3 ( 2008) Pre-delivery • Muffler- supporting arm fixing screws • Engine- supporting arm fixing screws Electrical system • Main switch • Lights: high beams, low beams, side/taillights (front and rear) and relevant warning lights - Regulating the headlights according to the regulations currently in force •...
  • Page 270: Static Test

    MSS Nexus 300 i.e. E3 ( 2008) Pre-delivery - Engine oil level Road test Test ride - Cold start - Instrument operations - Response to the throttle control - Stability on acceleration and braking - Rear and front brake efficiency - Rear and front suspension efficiency - Abnormal noise Static test...
  • Page 271 MSS Nexus 300 i.e. E3 ( 2008) Pre-delivery Specific operations for the vehicle Windshield fitting: - Remove the legshield upper cover. - Fit the indicated nut in the seat at the back of the windshield support brackets. - With the screws supplied fasten the windshield support brackets to the front frame .
  • Page 272 MSS Nexus 300 i.e. E3 ( 2008) Pre-delivery - Fit the three plastic spacers in the three rubber buffers. - Fit the central protection. - Fit the rubber protection on the windshield sup- port brackets, make sure that the clamps are cor- rectly snapped in the holes.
  • Page 273 MSS Nexus 300 i.e. E3 ( 2008) Pre-delivery - Fit the supplied cover caps in order to cover the holes not used. - Fit the windshield to the vehicle with the three screws supplied. PRE DE - 273...
  • Page 274 INDEX OF TOPICS TIME...
  • Page 275 MSS Nexus 300 i.e. E3 ( 2008) Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and re- fit.
  • Page 276 MSS Nexus 300 i.e. E3 ( 2008) Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 276...
  • Page 277: Cylinder Assy

    MSS Nexus 300 i.e. E3 ( 2008) Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001154 Pin-ring-piston assembly - Service 001129 Chain tightener - Overhaul and re- placement TIME - 277...
  • Page 278: Cylinder Head Assy

    MSS Nexus 300 i.e. E3 ( 2008) Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 001083 Thermistor - Replacement 001057 Thermostat - Replacement TIME - 278...
  • Page 279: Cylinder Head Cover

    MSS Nexus 300 i.e. E3 ( 2008) Time Rocker arms support assy. CAMSHAFT Code Action Duration 001148 Rocking lever valve - Replacement 001044 Camshaft - Replacement 001169 Decompressor - Replacement Cylinder head cover TIME - 279...
  • Page 280: Head Cover

    MSS Nexus 300 i.e. E3 ( 2008) Time HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001074 Oil vapour recovery pipe - Replace- ment Oil filter OIL FILTER Code Action Duration...
  • Page 281: Driven Pulley

    MSS Nexus 300 i.e. E3 ( 2008) Time Flywheel cover LYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001150 Flywheel cover gasket - Replace- ment 007007 Water pump rotor - Replacement 007017 Water pump cover - Replacement 007003 Coolant delivery and return pipe - Re- placement Driven pulley...
  • Page 282: Oil Pump

    MSS Nexus 300 i.e. E3 ( 2008) Time DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell - Replacement Oil pump OIL PUMP Code Action Duration 001125 Chain guide pads - Replacement 001051 Belt/Timing chain - Change...
  • Page 283 MSS Nexus 300 i.e. E3 ( 2008) Time Final gear assy. FINAL REDUCTION GEAR Code Action Duration 001010 Reduction gear - Replacement 003065 Gear box oil - Replacement 001156 Geared reduction unit cover - Re- placement 004125 Rear wheel axle - Replacement 004180 Reduction gear breather pipe - Re- placement...
  • Page 284: Driving Pulley

    MSS Nexus 300 i.e. E3 ( 2008) Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Driving belt - Replacement 001066 Driving pulley - Removal and refitting 001177 Variator rollers / shoes - Replace- ment 001141 Belt anti-flapping roller - Replace- ment...
  • Page 285: Transmission Cover

    MSS Nexus 300 i.e. E3 ( 2008) Time Transmission cover TRANSMISSION COVER Code Action Duration 001135 Transmission cover bearing - Re- placement 001096 Transmission crankcase cover - Re- placement 001131 Transmission air intake - Replace- ment 001065 Transmission cover - Replacement TIME - 285...
  • Page 286: Electrical Start-Up

    MSS Nexus 300 i.e. E3 ( 2008) Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001104 Start-up freewheel - Replacement 001151 Start-up driven gearing - Replace- ment 001017 Start-up pinion - Replacement TIME - 286...
  • Page 287: Magneto Flywheel

    MSS Nexus 300 i.e. E3 ( 2008) Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refitting 001173 Rotor - Replacement 001058 Complete flywheel - Replacement TIME - 287...
  • Page 288: Butterfly Valve

    MSS Nexus 300 i.e. E3 ( 2008) Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - Replacement TIME - 288...
  • Page 289: Exhaust Pipe

    MSS Nexus 300 i.e. E3 ( 2008) Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement 005138 Lambda probe - Replacement TIME - 289...
  • Page 290: Air Cleaner

    MSS Nexus 300 i.e. E3 ( 2008) Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor union - Re- placement 001027 Body / air cleaner union - Replace- ment TIME - 290...
  • Page 291 MSS Nexus 300 i.e. E3 ( 2008) Time Frame FRAME Code Action Duration 004001 Frame - replace 004146 Front frame - Replacement 001032 Engine support pin - Replacement TIME - 291...
  • Page 292: Centre-Stand

    MSS Nexus 300 i.e. E3 ( 2008) Time Centre-stand STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement TIME - 292...
  • Page 293 MSS Nexus 300 i.e. E3 ( 2008) Time Legshield spoiler FRONT SHIELD - SPOILER Code Action Duration 004066 Driving mirror - Replacement 005091 Turn indicator glass - Replacement 005067 Front direction indicator bulb - Re- placement 004064 Front shield - Replacement 004149 Shield central cover - Replacement 004065...
  • Page 294 MSS Nexus 300 i.e. E3 ( 2008) Time Side fairings IDE COVERS Code Action Duration 004068 One passenger grab handle - Re- placement 004085 Fairing (1) - Replacement 004012 Rear side panels - Replacement 004053 Spoiler - Replacement 004036 Frame cover - Replacement 004075 Front mat - Replacement 004059...
  • Page 295: Rear Cover

    MSS Nexus 300 i.e. E3 ( 2008) Time Rear cover HIELD BACK PLATE Code Action Duration 004065 Shield back plate - Replacement 004156 Glove box flap and/or support - Re- placement 004145 Glove box - Replacement 007024 Expansion tank cap - Replacement 004142 electric socket - Replacement 005085...
  • Page 296 MSS Nexus 300 i.e. E3 ( 2008) Time Central cover CENTRAL FRAME COVER Code Action Duration 004011 Central chassis cover - Replacement 004104 Left side cover - Replacement 004105 Right side cover - Replacement 004079 Rear footrest - Replacement 004143 Footrest support - replace TIME - 296...
  • Page 297 MSS Nexus 300 i.e. E3 ( 2008) Time ENTRAL COVER Code Action Duration 002082 Fuel tank cap opening drive - Re- placement 004135 Fuel tank lid - Replacement 004011 Frame central cover - Replacement TIME - 297...
  • Page 298 MSS Nexus 300 i.e. E3 ( 2008) Time Mudguard MUDGUARDS Code Action Duration 004167 Grill / radiator cover - replace 004009 Rear mudguard - Replacement 004002 Front mudguard - change 003087 Wheel housing - Replacement TIME - 298...
  • Page 299 MSS Nexus 300 i.e. E3 ( 2008) Time Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - replace 004170 Tank filler neck - Replacement 004168 Fuel filler flap - Replacement 004109 Fuel tank breather - replace TIME - 299...
  • Page 300: Rear Shock Absorber

    MSS Nexus 300 i.e. E3 ( 2008) Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Replacement TIME - 300...
  • Page 301: Handlebar Covers

    MSS Nexus 300 i.e. E3 ( 2008) Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 005129 Warning light group - Replacement 004156 Glove-box flap - Replacement 005038 Instrument panel warning light bulbs - Replacement...
  • Page 302: Handlebar Components

    MSS Nexus 300 i.e. E3 ( 2008) Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 005017 Stop switch - Replacement 002037 Brake or clutch lever - Replacement 002060 Complete gas command - Replace- ment 002059 Right hand grip - Replacement 003059 Counterweight - Replacement 002063...
  • Page 303 MSS Nexus 300 i.e. E3 ( 2008) Time Swing-arm WINGING ARM Code Action Duration 003081 Swinging arm supporting flange - Re- placement 004058 Silent-block - Replacement 001072 Engine/frame swinging arm attach- ment - Replacement TIME - 303...
  • Page 304 MSS Nexus 300 i.e. E3 ( 2008) Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004150 Saddle shock absorber - Replace- ment TIME - 304...
  • Page 305 MSS Nexus 300 i.e. E3 ( 2008) Time Instrument panel NSTRUMENT PANEL COMMANDS ON HANDLEBAR Code Action Duration 005078 Odometer glass - Replacement 005014 Odometer - Replacement 005006 Light switch or turn indicators - Re- placement 005039 Light switch - Replacement 005040 Horn button - Replacement 005121...
  • Page 306: Turn Signal Lights

    MSS Nexus 300 i.e. E3 ( 2008) Time Turn signal lights FRONT LIGHTS Code Action Duration 005002 Front headlamp - replace 005008 Front headlamp bulbs - replace 005044 Front lights cable unit - replace TIME - 306...
  • Page 307: Rear Lights

    MSS Nexus 300 i.e. E3 ( 2008) Time REAR LIGHTS Code Action Duration 005005 Taillight - change 005022 Rear turn indicators - Replacement 005068 Rear turn indicator bulb- Replace- ment 005091 Turn indicator glass - Replacement 005031 Licence plate light bulb - Replace- ment 004136 License plate holder support - Re-...
  • Page 308: Front Wheel

    MSS Nexus 300 i.e. E3 ( 2008) Time Front wheel FRONT WHEEL Code Action Duration 005089 Tone wheel - Replacement 002041 Front brake disc - Replacement 003037 Front wheel rim- Replacement 003038 Front wheel axle - Replacement 003040 Front wheel bearings - Replacement 003047 Front tyre - Replacement 003063...
  • Page 309: Rear Wheel

    MSS Nexus 300 i.e. E3 ( 2008) Time Rear wheel EAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 001071 Rear wheel rim - Replacement 004126 Rear wheel tyre - Replacement 002070 Rear brake disc - Replacement 003077 muffler/rear shock absorber support arm - Service TIME - 309...
  • Page 310: Electric Devices

    MSS Nexus 300 i.e. E3 ( 2008) Time Electric devices LECTRICAL DEVICES Code Action Duration 001094 Spark plug cap - Replacement 001069 HV coil - Replacement 005003 Horn - Replacement 005009 Voltage regulator - Replacement 005052 Fuse (1) - Replacement 005007 Battery - Replacement 005120...
  • Page 311: Helmet Compartment

    MSS Nexus 300 i.e. E3 ( 2008) Time Helmet bay HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - replace 005033 Glove-box light switch - Replace- ment 005026 Helmet compartment light - Replace- ment 004142 Plug socket - Replacement 005027 Helmet compartment bulb support - Replacement TIME - 311...
  • Page 312: Front Suspension

    MSS Nexus 300 i.e. E3 ( 2008) Time Front suspension RONT SUSPENSION Code Action Duration 003051 Complete fork - Replacement 003010 Front suspension - Service 003076 Fork sheath - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003002 Steering thrust washer - Replace- ment...
  • Page 313: Cooling System

    MSS Nexus 300 i.e. E3 ( 2008) Time Cooling system COOLING SYSTEM Code Action Duration 007002 Water cooling radiator - Replace- ment 007016 Fan with support - Replacement 007001 Expansion tank - Replacement 007024 Expansion tank cap - Replacement 007019 Coolant return pipe - replacement 007013 Expansion tank / radiator connecting...
  • Page 314 MSS Nexus 300 i.e. E3 ( 2008) Time Braking system RAKE SYSTEM Code Action Duration 002039 Front brake calliper - Replacement 002007 Front brake pads - Replacement 002021 Front brake piping - Replacement 002047 Front brake fluid and air bleeding system - Replacement 002020 Rear brake disc piping - Replace-...
  • Page 315 Air filter: 44 Battery: 68, 79–81, 265 Brake: 225, 227, 229, 230, 232, 233, 236 Coolant: 186 Engine oil: 44 Fuel: 163, 171, 262, 299 Fuses: 74 Headlight: 51, 246 Horn: 71 Hub oil: 42 Identification: 8 Instrument panel: 245, 305 Maintenance: 7, 40 Oil filter: 47, 280 Saddle:...

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2008 mss nexus 300 i.e. e3

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